However, if you're determined to attempt this yourself, here's a general overview of the steps involved. Remember, this is a *simplified* outline and may not cover every specific detail or variation for your particular vehicle. Always consult a repair manual specific to your 1999 Ford Windstar 3.8L for precise instructions and torque specifications.
General Steps (Simplified):
1. Disconnect the Battery: This is crucial for safety to prevent electrical shorts.
2. Drain the Refrigerant: You must recover the refrigerant using a proper HVAC refrigerant recovery/recycling machine. Releasing refrigerant into the atmosphere is illegal and harmful to the environment.
3. Remove the Dashboard: This is the most labor-intensive part. You'll need to remove various trim pieces, the steering column (possibly), the glove box, and potentially other components to access the evaporator core. This requires patience and careful documentation of each step to ensure proper reassembly.
4. Access the Evaporator: Once the dashboard is partially or fully removed, you'll locate the evaporator core behind the dashboard. Access may vary depending on the model. Expect to disconnect various ducts and hoses.
5. Disconnect the Evaporator: Disconnect all lines, electrical connectors, and any other connections to the evaporator core. Take pictures or videos to document the connections for reassembly.
6. Remove the Evaporator: Carefully remove the old evaporator core. This might involve removing retaining clips, bolts, or other fasteners.
7. Install the New Evaporator: Install the new evaporator core, ensuring all connections are secure and properly seated.
8. Reassemble Everything: Carefully reassemble all components, ensuring proper alignment and connection of all ducts, hoses, and electrical connectors. Refer to your repair manual for the correct order and procedure.
9. Reconnect the Refrigerant Lines: Reconnect the refrigerant lines.
10. Vacuum and Recharge the System: Use the HVAC refrigerant recovery/recycling machine to evacuate the system of air and moisture before charging it with the correct amount and type of refrigerant. Consult your vehicle's specifications for the proper refrigerant type and amount.
11. Test the System: Test the A/C system to ensure proper cooling and that there are no leaks.
Important Considerations:
* Repair Manual: A factory service manual or a reputable repair manual specific to your 1999 Ford Windstar 3.8L is absolutely essential. It will provide detailed diagrams, torque specifications, and step-by-step instructions.
* Tools: You'll need a variety of tools, including various screwdrivers (Phillips and flathead), sockets, wrenches, and potentially special tools for removing dashboard components. A refrigerant recovery/recycling machine is absolutely necessary.
* Safety: Work in a well-ventilated area. Refrigerant can be harmful if inhaled. Be aware of sharp edges and potential pinch points during disassembly.
Again, this is a challenging repair. If you're not comfortable with this level of automotive repair, take your vehicle to a professional mechanic. The cost of labor may be significant, but it's far less costly than potentially damaging other components during the repair process.
